Loveshaw CASEFORM 40 User manual

OPERATION - MAINTENANCE - & PARTS MANUAL
MACHINE MODEL
CASEFORM 40
THE LOVESHAW CORPORATION
2206 EASTON TURNPIKE, BOX 83
SOUTH CANAAN, PA.
18459
TEL. [phone]
SEPT/05 M.C.R. #05-022

TABLE OF CONTENTS
SECTION #1 MACHINE SPECIFICATIONS
SECTION #2 INSTALLATION
SECTION #3 SEQUENCE OF OPERATIONS
SECTION #4 SIZE CHANGE-OVER
SECTION #5 START UP PROCEDURE
SECTION #6 SHUT DOWN PROCEDURE
SECTION #7 MAINTENANCE SCHEDULE
SECTION #8 HOW TO ORDER PARTS
SECTION #9 SPARE PARTS LIST
SECTION #10 TROUBLE SHOOTING
SECTION #11 ILLUSTRATED ASSEMBLIES

MACHINE SPECIFICATIONS
MACHINE MODEL: CASEFORM 40
SERIAL NUMBER: ????
STANDARD DISCHARGE HEIGHT: 23"
AMERICAN ELECTRICAL
REQUIREMENTS:
PRIMARY VOLTAGE:
CONTROL VOLTAGE:
EUROPEAN ELECTRICAL
REQUIREMENTS:
PRIMARY VOLTAGE:
CONTROL VOLTAGE:
110 VOLTS, 1 PHASE, 60 HERTZ
110 VOLTS, 1 PHASE, 60 HERTZ
220 VOLTS, 1 PHASE, 50 HERTZ
220 VOLTS, 1 PHASE, 50 HERTZ
CASE CAPACITY:
LENGTH:
WIDTH:
HEIGHT:
7" (178mm) MIN. TO 24" (609mm) MAX.
6" (152mm) MIN. TO 16" (406mm) MAX.
4" (102mm) MIN. TO 16" (406mm) MAX.
FLIGHT BAR SPEED: 85 FEET / PER / MIN.
MACHINE SPEED: UP TO 14 CASES PER / MIN.
CLOSURE MATERIAL: 2" OR 3" PRESSURE SENSITIVE TAPE
MAXIMUM ROLL DIAMETER: 15"
AIR REQUIREMENTS: 11 S.C.F.M. AT 14 CASES PER /MIN.
AT 80 PSI.
MACHINE OPTIONS:
1. LOW TAPE ALARM.
2. LOW HOPPER ALARM
3. CASTERS .
4. LEVELING PADS
5. EUROPEAN GUARDING

INSTALLATION PROCEDURE
Exercise care when handling this machine. a sudden jolt or jar may cause serious
damage.
Do not remove the shipping skid until machine has been moved to a point of
installation. The skid is designed for easy and safe handling of your machine.
Raise or lower the machine to the desired operating elevation using the leveling jack
screws and level the machine.
A great deal of trouble may be caused if the current is supplied by lines which are
not heavy enough. if this occurs, the motors and controls cannot operate at their full
capacity and over heating may result. A similar condition will exist if poor electrical
connections are made. It's therefore worthwhile to make sure that everything is
electrically correct.
Electrical polarity must be supplied to the machine exactly as shown on the electrical
diagram. Power must be supplied to L1 side of the circuit and the L2 side will be
neutral. If this is not correct, the circuit protectors (ECP 1) will trip out because of a
short circuit.
The air to the machine should be clean and dry, as the filter is only meant to remove
minor particles or slight amounts of moisture. Dirt or moisture in the air line can
cause the erratic operation of control valves.
Connect the air supply to an air source with a minimum line pressure of 80 PSI.
Before starting the machine, load the tape cartridge with tape and thread the tape.
See threading diagram on tape unit.
For proper start-up procedure see the start-up procedure section of this manual.

SEQUENCE OF OPERATION
INITIAL CONDITIONS:
A. MAIN AIR ON
B. POWER SWITCH OFF.
C. VACUUM CUP TROLLEY CYLINDER IS EXTENDED. (SOL. 5)
D. MINOR FLAP FOLDER CYLINDERS ARE RETRACTED. (SOL. 6)
E. CASE PUSHER CYLINDER IS RETRACTED. (SOL. 4)
F. VACUUM SWITCH IS ON.
GENERAL SEQUENCE:
1. Press the "START" push-button (PB 2). Motor contactor (M1) is energized and
the motor starts.
2. Normally open contact (M1) closes, programmable controller is energized, and
the sequence starts.
3. The case pusher and vacuum cup trolley go to home position.
4. As soon as proximity switches 2 and 3 are activated , the vacuum cup trolley
(output 102) moves forward to pick-up a blank.
5. At the extended position, the vacuum cup trolley activates proximity switch 1
(input 002) energizing timer 4. After a pre-set time, timer 4 times out, de-energizing
vacuum cup trolley solenoid (output 102).
6. The vacuum cup trolley then returns to the home position, activating proximity
switch 2 (input 003) energizing the minor bottom flap folders (output 104).
7. Proximity switch 2 energizes timer 3. After a preset time, timer 3 times out de-
energizing the vacuum solenoid (output 103). The formed case is released, ready
for case transfer.
8. As the chain lug is detected by photocell 1 (PC 1), the internal relay 1004 turns on
the case pusher solenoid (output 106), allowing the case pusher to move forward
and push the formed case towards the feed rollers, and then into the chain lug drive.

9. At the extended position of the case pusher, proximity switch 4 (Prox. 4) is
activated, energizing the internal relay 1003. This relay then de-energizes the case
pusher extend solenoid (output 106), sending the case pusher back to the home
position.
10. As output 106 is de-energized, timer 6 starts timing. When timer 6 times out, the
minor flap folder solenoid (output 104) is de-activated. The machine is now ready
for the next cycle.
11. Repeat sequence starting at general sequence #5.
NOTE 1: PC 2 is located downstream from the machine. During normal production,
this switch being closed, will signal the case pusher to push the next formed case
out of the forming area.
NOTE 2: SLS 1 and SLS 2 open when safety door is opened. The motor then
stops and all the air cylinders will loose air pressure. The safety doors must be
closed to re-start the machine.
NOTE 3: Pushing the cycle button on the hand-held control station or if contact with
the downstream photocell (PC 2) is made, will activate the machine to feed a case
into the taping section.
NOTE 4: All machine motions are pneumatically controlled from sequence
switching, which will not allow a defective case to be discharged from the machine.

CONTROL DESCRIPTION
SLS 1 SAFETY LIMIT SWITCH OPERATES WHEN SAFETY GATE IS
CLOSED.
SLS 2 SAFETY LIMIT SWITCH OPERATES WHEN SAFETY GATE IS
CLOSED.
PROX. 1 PROXIMITY SWITCH ACTIVATES WHEN TROLLEY IS HOME.
PROX. 2 PROXIMITY SWITCH ACTIVATES WHEN TROLLEY IS PICKING
BOX.
PROX. 3 PROXIMITY SWITCH ACTIVATES WHEN CASE PUSHER IS
RETRACTED.
PROX. 4 PROXIMITY SWITCH ACTIVATES WHEN CASE PUSHER IS
EXTENDED.
PROX. 5 BLANK HOPPER DRIVE SAFETY.
SOL 1 CONTROLS AIR SUPPLY TO SOLENOID VALVES.
SOL 2 CONTROLS VACUUM ON / OFF.
SOL 3 CONTROLS BLANK HOPPER DRIVE.
SOL 4 CONTROLS FORWARD MOVEMENT OF CASE PUSHER.
SOL 5 CONTROLS MOVEMENT OF TROLLEY.
SOL 6 CONTROLS MOVEMENT OF FLAP TUCKERS.
PC 1 SENSES CHAIN PUSHER LUG.
PC 2 CASE DEMAND SWITCH IS ACTIVATED WHEN THERE IS NO BOX
IN FRONT OF SENSOR.
PC 3 CYCLE START BUTTON.
SS 1 VACUUM OFF / ON SWITCH.

SIZE CHANGE OVER
NOTE:
TURN POWER OFF BEFORE MAKING ANY ADJUSTMENTS TO
THIS MACHINE.
HOPPER DRIVE ASSEMBLY
(C622922)
A. HOPPER WIDTH ADJUSTMENT:
TO SET, Loosen ratchet handle (item #19) and turn handknob (item #20) until the
blank that is about to be run fits loosely between the adjustable blank guide (item
#14) and the fixed side blank guide (item # 23).
Tighten ratchet handle before starting machine.
B. HOPPER BOTTOM FINGER ADJUSTMENT:
TO SET, The case bottom finger will need to be adjusted for almost every different
case size handled by the machine. This finger must be positioned in a manner as to
slip through the slots of the knock-down case at the manufacturers joint and slightly
hold the inside rear panel, as the vacuum cups pull the case from the hopper. This
finger aids in forming the knock-down case by breaking the case at the scoring.
Set the finger so that it is approximately 3/8" from the front face of the case and 1/4"
deep into the slot.
HOPPER FRAME ASSEMBLY
(C622920)
HOPPER HEIGHT ADJUSTMENT:
To adjust the hopper height rotate the handle on the top of the hydraulic pump (item
#10) clockwise for raising and anti-clockwise to lower.
You can set this adjustment using the scale on the side of the hydraulic cylinder
(item #6), divide the width of the case in 2, and set the pointer (item #21) to that
position on the scale.
When you are finished adjusting this assembly put the handle on the hydraulic pump
back into its locked position.
EXAMPLE: If the case you are running is 10" wide, you would set the pointer to 5"
on the scale.

FRONT FLAP FOLDER ASSEMBLY
(C622911-1)
There are no adjustments needed for the front flap folder assembly, other than
cylinder cushion adjustment, if required, and folder plate change parts.
REAR FLAP FOLDER ASSEMBLY
(C622264)
A. CASE PUSHER ASSEMBLY
TO SET, Loosen ratchet handles (item #10) and slide the rear flap folder assembly
until the pusher plate (item #9) is approximately a 1/4"away from the rear edge of the
formed carton, as it sits erected on the bottom flap folders.
You can set this adjustment using the scale on item #7.
Tighten ratchet handles before starting machine
EXAMPLE: If the case you are running is 16" long, you would set the pointer to 16"
on the scale.
B: REAR FLAP FOLDER ASSEMBLY
There are no adjustments needed for the rear flap folder, other than cylinder cushion
adjustment, if required, and folder plate change parts.
FORMING GUIDE ASSEMBLY
(C622277)
The forming guide assembly starts to fold the case end panel as the knock-down
case is pulled from the hopper, across the front face of the case pusher.
TO SET, Arrange the guide assembly so that a gradual transfer is obtained as the
knock-down case is pulled from the hopper across the forming guide, to the front of
the pusher plate. The forming guide assembly should be set so that the roller strikes
the center of the case.
Make sure to tighten all nuts and bolts on this assembly before starting machine.

TOP FINGER ASSEMBLY
(C622276)
TO SET, The case top finger will need to be adjusted for almost every different case
size handled by the machine. This finger must be positioned in a manner as to slip
through the slots of the knock-down case at the manufacturers joint and slightly hold
the inside rear panel, as the vacuum cups pull the case from the hopper. This finger
aids in forming the knock-down case by breaking the case at the scoring.
Set the finger so that it is approximately 3/8" from the front face of the case and 1/4"
deep into the slot.
VACUUM TROLLEY ASSEMBLY
(C622268)
A. CASE LENGTH ADJUSTMENT:
TO SET, Loosen ratchet handle (item #18) and slide the whole assembly across
until the center of the vacuum post (item #5) is centered on the center of the blank
length panel, or you can set this adjustment using the scale on the frame under the
U-channel (item #2), divide the length of the case in 2, and set the trolley assembly
to that position on the scale.
Tighten ratchet handle before starting machine.
EXAMPLE: If the case you are running is 16" long, you would set the vacuum cup
trolley to 8" on the scale.
B. CASE WIDTH ADJUSTMENT:
TO SET, Loosen ratchet handle (item #9) and slide the stop bracket (item #5) until
the center of the formed carton, as it sits erected on the bottom flap folders is always
at the center line of the machine. You can set this adjustment using the scale under
the stop bracket (item #5), divide the width of the case in 2, and set the back of the
stop bracket (item #5) to that position on the scale.
EXAMPLE: If the case you are running is 10" wide, you would set the stop bracket
to 5" on the scale.